Reciprocating motion signature monitoring and trend analysis system

Abstract

A diverter system includes a diverter arm operated by an actuator assembly. The actuator assembly moves the diverter arm between an extended dwell position and a retracted dwell position. The position of the diverter arm is monitored by a sensor. A control system derives a motion signature of the diverter arm based on the positions of the diverter arm measured by the sensor and evaluates the motion signature of the diverter arm to identify an abnormal operation of the diverter arm.

The invention claimed is: 
     
       1. A diverter system comprising:
 a diverter arm, 
 an actuator assembly for operating the diverter arm, the actuator assembly configured to move the diverter arm between an extended dwell position and a retracted dwell position, 
 a sensor for monitoring a position of the diverter arm, and 
 a control system configured to derive a motion signature of the diverter arm based on the positions of the diverter arm measured by the sensor, and to evaluate the motion signature of the diverter arm to identify an abnormal operation of the diverter arm, 
 wherein the control system is configured to compare the motion signature of the diverter arm to a previously stored reference signature of a reference diverter arm to identify an abnormal operation of the diverter arm, wherein the comparison comprises determining a degree of difference between the dwell positions of the diverter arm and reference dwell position of the reference signature. 
 
     
     
       2. The diverter system of  claim 1 , wherein the control system is configured to compare the motion signature of the diverter arm to one or more fixed thresholds to identify an abnormal operation of the diverter arm. 
     
     
       3. The diverter system of  claim 1 , wherein the control system is configured to communicate evaluated motion signature to a remote cloud-based application or a remote database via a wireless communication link. 
     
     
       4. A diverter system comprising:
 a diverter arm, 
 an actuator assembly for operating the diverter arm, the actuator assembly configured to move the diverter arm between an extended dwell position and a retracted dwell position, 
 a sensor for monitoring a position of the diverter arm, and 
 a control system configured to derive a motion signature of the diverter arm based on the positions of the diverter arm measured by the sensor, and to evaluate the motion signature of the diverter arm to identify an abnormal operation of the diverter arm, 
 wherein the sensor comprises at least one accelerometer affixed to the diverter arm. 
 
     
     
       5. A diverter system comprising:
 a diverter arm, 
 an actuator assembly for operating the diverter arm, the actuator assembly configured to move the diverter arm between an extended dwell position and a retracted dwell position, 
 a sensor for monitoring a position of the diverter arm, and 
 a control system configured to derive a motion signature of the diverter arm based on the positions of the diverter arm measured by the sensor, and to evaluate the motion signature of the diverter arm to identify an abnormal operation of the diverter arm, 
 wherein the actuator assembly comprises a servo-controlled motor configured to control the position of the diverter arm based a command signal that is adjusted as a function of an error between a setpoint position and an actual position measured by the sensor, wherein control system is configured to derive the motion signature of the diverter arm based on a change of the command signal at discrete time steps. 
 
     
     
       6. The diverter system of  claim 5 , wherein the control system is configured to determine the motion signature of the diverter arm as a summation of command signal change occurring at discrete time steps over a defined interval. 
     
     
       7. The diverter system of  claim 6 , wherein the defined interval corresponds to one or multiple reciprocating cycles of the diverter arm. 
     
     
       8. The diverter system of  claim 6 , wherein the control system is configured to compare the summation of command signal change to a reference value to identify an abnormal operation of the diverter arm. 
     
     
       9. The diverter system of  claim 5 , wherein the command signal is a current signal for controlling torque applied to a motor shaft. 
     
     
       10. The diverter system of  claim 5 , wherein the sensor comprises a rotary encoder affixed to a motor shaft. 
     
     
       11. A diverter system comprising:
 a diverter arm, 
 an actuator assembly comprising a servo-controlled motor for moving the diverter arm between an extended dwell position and a retracted dwell position, the servo-controlled motor configured to control the position of the diverter arm based on a command signal that is adjusted as a function of an error between a setpoint position and an actual position, and 
 a control system configured to derive a motion signature of the diverter arm based on an error count over a defined interval and to evaluate the motion signature of the diverter arm to identify an abnormal operation of the diverter arm.